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By: R. P. Naik
DGM (MM)
NTPC, Sipat
In NTPC, we are relying on only vibration measurement as basic technique for condition
monitoring of bearings. Some times Infrared temperature detectors are also used but their
use becomes necessary mainly when temperature monitoring becomes important.
A new technique called Ultrasonic condition monitoring is now available which can
detect even incipient faults in bearings as well as adequacy of lubricant. IRD
measurements are generally not use full for very slow speeds but ultrasonic detector can
be used even in slow speed machines such as APH guide / support bearings etc. This
technology can be considered an integrating technology since it can be used with infrared
and vibration inspections as well as stand alone to perform a multiplicity of inspection
activities. Instruments based on this technology can monitor a wide range of plant
operations and yet are simple enough to be used with minimal training for basic, effective
inspection routines.
Many failures and repairs that commonly occur in the industrial setting can be prevented
with ultrasonic technology, a highly effective non-destructive, predictive maintenance
method.
Consider the following summary from a third party evaluation team for the integration of
ultrasonic technology in a single organization with over 500 sites:
• More than 100 applications were identified in use for various equipment at each
site such as boilers, heat exchangers, compressors, motors, pumps, valves, and
steam traps.
• The total savings for the organization would be approximately $3.7 million
annually.
• The return on investment for the integration of ultrasound with this cost avoidance
would be approximately 15:1.
• The annual man-year savings caused by the reduction of time spent diagnosing
and troubleshooting would be approximately 45 man-years.
Although the ability to gauge intensity and view sonic patterns is important, it is equally
important to be able to "hear" the ultrasounds produced by various equipment. That is
precisely what makes these instruments so popular. They allow inspectors to confirm a
diagnosis on the spot by being able to clearly discriminate among various equipment
sounds. This is accomplished in most ultrasonic instruments by an electronic process
called "heterodyning" that accurately translates the ultrasounds sensed by the instrument
into the audible range where users can hear and recognize them through headphones.
Condition Monitoring
Condition monitoring and predictive maintenance has traditionally been performed
through vibration analysis, infrared, and other technologies. Ultrasonic technology is an
excellent option, especially for organizations with lower budgets. Ultrasonic detectors are
capable of accurately interpreting the sounds created by under lubrication, over
lubrication, and early signs of wear. The right ultrasonic technology is a fast and effective
means of determining such conditions in moving, mechanical components such as
bearings, gearboxes, motors, compressors, etc.
In addition, once a bearing begins to wear, the ultrasonic wave will produce large spikes
in the signal caused by flat spots or scratches on the race. The spikes are heard as pops or
crackles through the headset. Once the ultrasound produced by the bearing begins to
indicate these characteristics, the replacement of the bearing can be planned during
normal production shutdown. The detection of wear is instantaneous. It is not necessary
to take readings of the bearing from several points of contact along different axes and
send the readings away for analysis.
The use of ultrasound technology for condition monitoring does not need to be complex,
however. Software may be used to record the output of the ultrasonic sensor. Once a
baseline or benchmark signal of a component is recorded (see Fig. 2), future recordings
may be compared to it in order to determine the wear or proper lubrication of the
component over time.
INSTRUMENTATION
Airborne Ultrasound translators are relatively simple to use. They consist of a basic hand
held unit with headphones, a display panel, a sensitivity adjustment, and (most often)
interchangeable modules that are used in either a scanning (airborne) mode or a contact
(structure borne) mode. Some instruments have the ability to adjust the frequency
response from between 20 to 100 kHz. Ultrasound instruments may be analog or digital.
Digital instruments indicate intensities as decibels. Digital instruments generally have
onboard data logging with data management software to provide trending information
and create alarm groups for equipment needing special attention. Some of the digital
instruments also have on-board sound recording, which enables users to grab sound
samples and review them on spectral analysis software.
APPLICATIONS
Generically, applications for ultrasonic translators fall under three basic categories:
mechanical inspection, leak detection and electrical inspection.
MECHANICAL INSPECTION
Mechanical equipment produces a "normal" sound signature while operating effectively.
As components begin to fail a change in the original sonic signature occurs. This change
can be noted as a shift in intensity on a display panel and/or as a qualitative sound change
that can be heard through headphones and recorded for further analysis. An ultrasonic
translator may be connected to a vibration analyzer or the sound samples may be
reviewed through spectral analysis software on a PC.
Leak detection
The reason ultrasound is so versatile is that it detects the sound of a leak. When a fluid
(liquid or gas) leaks, it moves from the high-pressure side of a leak through the leak site
to the low-pressure side where it expands rapidly and produces a turbulent flow. This
turbulence has strong ultrasonic components. The intensity of the ultrasonic signal falls
off rapidly from the source. For this reason the exact spot of a leak can be located. This
can apply to pressure leaks, such as compressed air, and negative pressure (vacuum)
leaks, leaks in valves and in steam traps.
Reciprocating compressor valves are very noisy and produce a lot of extraneous
vibration. By isolating the sound with the advantage of the short-wave nature of
ultrasound, it is possible to listen to and view the sounds of these noisy valves in real time
and to determine a leaking valve. As it opens and closes there will be a definite,
pronounced clicking sound & sound from any leaking valve will be clearly
distinguishable from normal valves. Similarly many other steam, air & or H2 leakages
also can be located by these instruments.
When a leak occurs, the turbulent flow produces sound pressure waves all along the
spectrum from 0 Hz to100 kHz and beyond. Lower frequency sounds travel greater
distances and interfere with ambient noise such as running machinery. Also, these sounds
have greater energy and can easily reflect off surfaces, minimizing the ability of a low
frequency microphone to accurately locate the leak. High frequency waves (those far
above 40 kHz) do not have sufficient energy to be detectable from reasonable distances.
An ultrasonic sensor that is used for the detection and location of leaks should:
• Have a narrow bandwidth with center of frequency 40 kHz
• Have a narrow directional pattern of reception
• Have controls for adjusting the sensitivity of the receiver in order to pinpoint
location
• Have an analog meter, that rapidly displays small changes in the input signal
• Have a good signal-to-noise ratio as noise will minimize the sensor’s ability to
detect a leak
• Have a long battery life
Electrical Emissions
Some preliminary experimentation has demonstrated that the main harmonic of an
electrical emission (60 Hz in the USA, 50 Hz elsewhere) will be most prevalent in
corona. As the condition becomes more severe, there will be fewer and fewer 60/50 Hz
harmonics observed. As an example, arcing has very few 60/50-cycle components.
Mechanical looseness will demonstrate harmonics other than 60/50 Hz with little to no
frequency content between peaks.
Lubrication
As the concept of “Predictive” lubrication versus time-based (“Preventive”) lubrication
has emerged, there are times when it is useful to use spectral analysis combined with
sound. Instead of lubricating bearings on a routine, “time-based” schedule, inspectors can
routinely test bearings and identify those that need lubrication, leaving the others alone.
In this manner, lubrication technicians can be taught how to effectively apply just enough
lubricant to prevent over lubrication.
When a bearing has exceeded a baseline by 8 dB with no change in acoustic quality, the
bearing should be lubricated. While applying lubrication, the technician should stop when
the sound level has dropped to the pre-determined baseline level. A way to demonstrate
this process is to view a sound image while noting changes In amplitude and listening to
acoustic properties in real time.
However, before going for this technology, we must consider the following turnkey
implementation program for ultrasonic technology integration:
Conclusion
Airborne ultrasound instruments are becoming an important part of Condition
Monitoring, Fugitive Emissions and Energy Conservation programs. Their versatility,
ease of use and portability enable managers to effectively plan and implement inspection
procedures. By locating leaks, detecting high voltage electrical emissions and sensing
early warning of mechanical failure, these instruments contribute to cost reductions,
improved system efficiencies and reduced downtime. For optimum effectiveness, it is
recommended that all major technologies, infrared, vibration and ultrasound, be used as
part of a comprehensive inspection program.
If properly implemented and used on a regular basis, ultrasound technology can be a fast,
cost effective means of monitoring critical components at our plants. The approach to
implementation should include the right product, training of personnel, identification of
critical components, benchmarking, and the determination to follow through on good
intentions. A lack of training and understanding, irregular monitoring, and a lack of
commitment to the predictive maintenance program will lead to poor results. However,
proper implementation of ultrasonic technology will increase reliability, decrease
troubleshooting time, and decrease time spent putting out fires by our operation &
maintenance staffs
References:
• www.UEsystems.com: White paper on condition monitoring
• www.syguruace.com: Ultrasonic leak detection
• www.ctrlsys.com: Ultrasonic condition monitoring more than just a leak
detector